Process of making reenforced concrete structures



J. T. SIMPSON. PROCESS OF MAKING REENFORCED CONCRETE STRUCTURES.

APPLICATION FILED JAN. 25' I918.

PatentedSept. 5, 1922.

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Patented Sept. 5, 1922.

' entree stares JOHN T. snvirson, OENEWARK, NEW JERSEY.

PROCESS OF MAKING REENFOBCED CONCRETE STRUCTURES,

Application filed January 25, 1918; SerialNo. 213,640.

T 0 aZZ to hem it may concern:

Be it known that I, JOHN T. SIMPSON, a citizen of the United States, and a resident of Newark, in the county of Essex and State of New Jersey, have invented a certain new and useful Process of Making Reenforced Concrete Structures, of which the following is a specification.

My invention relates to processes of building concrete structures wherein reenforced concrete shop cast elements are united by and to field cast reenforced concrete elements, and is directed more particularly to the construction of buoyant vessels such as boats,

barges, lighters and ships for marine transportation.

The objects of my invention are to improve the strength and durability of the structure, to expedite the construction, reduce the cost, improve the appearance and reduce the expense of transportation of materials to the point where the structure is to be erected.

These and further objects will more fully appear in the following'specification and. accompanying drawings considered together or separately. v

I have illustrated one embodiment of my invention in the accompanying drawings in which like parts in all of the several figures are designated by similar characters of reference, and in which I Figure l is a deck plan view of a barge or lighter constructed according to my process. i

Figure 2 is a fore and aft section or in;

board profile of the same taken on the line 2-2 of Figure 1.

' Figure 3 is a transverse section, on an enlarged scale, taken on the line 3-3 of Fig ure 1. Y

- Figure 4. is a view similar'to Figure 3 but showing the shop cast skin plates in position to receive the field. cast elements.

Figure 5 is a detail section showingthe mold in position to produce that portion shown in the dotted circle a: of Figure 3.

Figure 6 is a detail section on the line indicated by 6-6 of Figure 2 showing the keel mold in position.

Figure 7 is a detail section onthe line indicated by 77 in Figure 3 showing the mold for a stanchion and for supporting the shop cast bulkheads.

Figure 8 is a detail section on the line indicated by 88 in Figure 1 showing a structure comprising shop .cast elements or 7 plates and field cast elements, the two being comblned and permanently connected together to form a monolithic structure by the operation of molding the field cast elements.

By shop-cast elements I mean those portions of the structure which are not molded during the construction of'the vessel. These elements are manufactured in factory which may be at a great distance from t-hepoint of assembly. They may be machine cast in a well equipped shop. 1 Each of the different shapes required will be the exact counterpart'of the other shapes of its size. The surfaces will 'be smooth. The parts may be artificially dried and seasoned thereby speeding'up construction. The cost will be greatly reduced. One shop may turn out sufiicient shapes to keep several assem bling plants busy. The shop cast shapes are few in number and vessels of any size 7 and tonnage may be constructed. The liability of producing defective work will be reduced to a minimum and inspection will be greatly facilitated. 'By I field cast? elements parts of the vessel which are molded during the operation of assembling the ,shop cast elements at the waterside in. order that the finished structure may be launched. The

I mean those elements are combined so that the field cast part will interlock with the reinforcements of the shop cast parts and forma unitary structure. The'field cast and shop cast elements are further locked together to prevent separationof the partsdueto strains. The shop cast elements form part ofthe mold of the other elements and the wetted portion of the hull of the vessel is composed entirely of shop cast elements. In the drawings 1 designates a decked barge or lighter which may be of any desired length, beam and depth of hold. .The hull is composed of deck plates 2, sides plates 3 and bottom plates 4, all composed'of shop cast reenforced concrete slabs. Each of the lateral molds and may be supported and side of the mold 30 may be forced into intimate'contact with the inside of the. skin plates by the following instrumentalities.

The reinforcements of the plates project into the mold. A wire 31 bent'upon itself to form a staple is passed through perfora tions in the wall ofthe mold 30 opposite the'plates. fast to the reinforcements projecting from the plates. Between the bend of the wire 31 and the outer surface of the mold a wedge '32 is driven. This will draw the open side of the mold into close contact with the inside of the plates. A filling opening 33 may be left in the top side of the mold. and concrete may be poured. therein until the vertical molds'and the mold 230 are filled to the level of. the top wall of the latter and forms a ribbon 33 or shelf extendingentirely around the hull.

The hull is built up in the above described manner until the required height is attained.

A mold is now placed around the entire upper edge 'of the hull and encloses the-up per edges of'the upper row of plates and their projecting reinforcements. This mold will. define a. heavysillfli which will encircle the" structure. Horizontal lateral molds in alinement with the ribs, and longitu'dinal' molds in alinement withthe bottom beams are now placed inposition resting on and communicating with the molds of the vertical extensions of theribs and beams and the stanchions and define deck beams 35. Proper reinforcing members are placed in the sill andrdeckbeam molds and the reinforcements of the plates, ribs, bulkheads and stanchions project into such molds. Bolts 36 are placed within the sill mold and projectthrough the outer wall thereof. The

outer wall of the sill mold is somewhat the deck beam molds.

All of the molds are provided with wires higher than its inner wall and the walls of.

. such as 37 passing through alined perforations in opposite walls thereof. These wires are for the purpose of maintaining the reinforcing members in position before and dur ing the field casting operation.

Concrete is now poured into the above described molds embedding the reinforcements therein and the projecting edges of the skin plates and bulkheads and their projecting reinforcements.

Deck plates 2 are now laid in position resting on the deck beams and sill with spaces between their contiguous edges. The reinforcements of the deck platesproject into the spaces. The spaces between deck plates and the top ofthe sill mold to the level of the tops of such plates are filled with concrete flush with the tops of the plates. Certain of the reinforcements of the'deck The ends of this wire are made of the members.

beams. and thoseofthe ribs and stanchions may also project into such spaces and thereby bind the parts with closer relation.

Certain of the deckplat'es 2 are-provided with openings to form 'hatches38." When the deck plates are in position a mold 38 is placed around the edges of each hatch and reinforcements are placed in each mold. The projecting reinforcements of the plates are bent up and'over suchrreinforcements and the molds are filled with concrete for forming hatch combings 39. A top dressing and set the wedges 82 are removed and the loop of the wire 31 is" severed; The molds are then removed, the projecting-ends of the'wires 31 arecut oif flush'with the sur-- faces from which they project. The wires 37 may be withdrawn from the members in j which they rest or the'projecting ends of the wires are cutofi flush with the surfaces I Certain parts ofv the cradle -may be removed and the vessel it launched in the usual manner or it may be launched in the cr'adleiasis'common'.

Before and during the'casting and drying of the field molded members the plates are securely held in position from the out;

side by the cradle and-from theinside by I a system of troughs which cover every seam and some of which extend from the bottom plates to the level of the deck plates; The seam covering troughs being arrangedfrelatively close together andbeing braced by the floor beam and deck beam troughswhich are braced by the stanchion troughs" will be sufficient to support the plates in position during the casting and drying operations; it being understood that additional braclng may be employed 1f deslredfi In-the building of a house assh'own in I Figure 9 the same processislcarried out with the exception that bottom plates, such as 4v and 9, need not be employed, but such plates may be used in certain structures such as warehouses on piers. In constructing a house by my process the door, window and other openings will be formed as are the hatches and the frames andsills of such may be formed in the same manner as are the hatch combings. I H I i I desire to have itunderstood thatinstead of setting up the entire skinsurface of the hull before the'molding of the *fieldcast members is proceeded (with, the plates may be erected in belts and the field cast elements will be molded as new belts'are placed in position.

The shop cast elements are few in num her as regards size and shape and vessels of any size and tonnage may be constructed by employing a greater or lesser number o'l plates between the bows and stern.

It will, of course, be understood that all o1 the molds for the field elements may be secured to the reinforcements projecting from the shop cast elements in the same manner that the mole S'Ois drawn up tothe side plates.

In accordance with the provisions of the patent statutes, 1 have described the principles of my invention, together with the specific method of operation which T consider to best illustrate-the same, but I desire to have it understood that such method of operation is merely illustrative, and that the invention may be carried out in other ways.

Having now described my invention what I claim and desire to secure by Letters Patent of the United States is:

1. The herein described process, which consists in setting up shop-cast reenl orced concrete elements in alinement with their edges in contact, there being a groove in the edges of each plate, the grooves of ad joining plates being in alinement, calking the grooves from the inside forming molds on the inside of the structure and enclos ing all of the seams between the elements, introducing concrete into the molds, and then removing the molds.

2. The herein described process, which consists in setting up reentorced shop cast elements in alinement with their edges in contact, there being a groove in each edge of each element, the grooves of adjoining elementsbeing oppositely disposed thereby forminga recess in each joint between elements, the joints being open on one side of the elements thereby permitting access to the recess from the inside, calking the recess and joint from the inside, andmolding a reentorced concrete element over the joint.

3. The herein described process, which consists in setting up reentorced shop cast elements in alinement with their edges in contact, the edges of the elements being thickened, the reinforcements projecting at approximately a right angle from the thickened portions, there being a groove in the thickened portions 01" eachv element," the grooves of adjoining elements being oppositely disposed thereby forming a recess in each joint between the elements, the joints being open on one side of the elements thereby permitting access to the recess from the inside, calking the recess and joint from the inside, forming a mold enclosing the thickened portions and projecting reinforcements, placing reinforcing members in the molds and supporting said members in position, introducing concrete into the molds, removing the supports, and then re moving the molds.

4:. The herein described process, which consists in setting reenforced concrete ele ments in alignment, "forming a mold on one side'of the elements enclosingthe joints between the elements whereby the elements become part of the'mold, therebeing1reinforcements of the elements projectingiinto the mold, securing wires tosaid reinforcements, there being loops formed on said wires extending outside of said 'm0ld,'forcmg wedges into said loopsto securely fasten said mold into place, introduoingc'oncrete into mold, and then removing the mold.

5. The herein described process which consists in setting 'reeniorced concrete ele ments in alignment, setting-up mold plates on one side of the elements to enclose the joints between the elements whereby the elements become part of the mold, there be ing reinforcements of the elements: projecting into the mold, passing-both endsof U- shaped wires through one of the mold plates, securing both ends'o'f the'w'ires to the reinforcements of said elements, then forcing wedges between the protruding loops of the ti -shaped wires andthe mold plates to securely fasten said mold plates into )lace introducing con rete into'th'emold 1 3 L) 7 and then removing the mold. This specification slgned and w tnessed this QA-th day of, January, 1918.'

JOHN T. SIMPSON.

Witnesses:

JAs. F. COLEMAN, A. E. BENTON. 

